Improved alkoxylation process

Abstract

The present invention relates to a method for preparing a fatty-chain high-molecular-weight alkoxylate, comprising treating the reaction medium with an acid having a pK a of 3.5 or less.

1 - 11 . (canceled) 
     
     
         12 . A process for preparing a compound of formula (I): 
       
         
           
           
               
               
           
         
       
       where:
 R represents a linear or branched hydrocarbon-based fatty chain comprising from 8 to 60 carbon atoms; 
 Ak represents an alkylene unit with 2 carbon atoms, 3 carbon atoms, or 4 carbon atoms; and 
 n is an integer from 10 to 250; 
 the process comprising:
 reacting a compound having formula R-OH, where R is as defined in formula (I), with at least one alkylene oxide, in the presence of a catalyst to produce a reaction medium; 
 treating the reaction medium with an acid having a pK a  of less than or equal to 3.5 to produce a neutralized reaction medium; and 
 recovering the compound of formula (I) by treating the neutralized reaction medium. 
 
     
     
         13 . The process of  claim 12 , wherein R of formula (I) and formula R-OH represents a linear or branched hydrocarbon-based fatty chain comprising from 8 to 60 carbon atoms, wherein the hydrocarbon-based fatty chain is saturated or unsaturated and optionally includes:
 one or more saturated rings; or   one or more partially unsaturated rings; or   one or more completely unsaturated rings; or   one or more oxygen atoms in an ether functionality, an alcohol functionality, an acid functionality, or an ester functionality; or   any combination of these.   
     
     
         14 . The process of  claim 12 , wherein R of formula (I) represents a linear or branched hydrocarbon-based fatty chain comprising from 8 to 40 carbon atoms, wherein the hydrocarbon-based fatty chain is saturated or unsaturated and optionally includes:
 one or more saturated rings; or   one or more partially unsaturated rings; or   one or more completely unsaturated rings; or   one or more oxygen atoms in an ether functionality, an alcohol functionality, an acid functionality, or an ester functionality; or   any combination of these.   
     
     
         15 . The process of  claim 12 , wherein R of formula (I) represents a linear or branched hydrocarbon-based fatty chain comprising from 10 to 30 carbon atoms, wherein the hydrocarbon-based fatty chain is saturated or unsaturated and optionally includes:
 one or more saturated rings; or   one or more partially unsaturated rings; or   one or more completely unsaturated rings; or   one or more oxygen atoms in an ether functionality, an alcohol functionality, an acid functionality, or an ester functionality; or   any combination of these.   
     
     
         16 . The process of  claim 12 , wherein n of formula (I) is an integer from 15 to 200. 
     
     
         17 . The process of  claim 12 , wherein n of formula (I) is an integer from 18 to 160. 
     
     
         18 . The process of  claim 12 , wherein the compound of the formula R-OH is selected from the group consisting of fatty alcohols, fatty acids, fatty polyacids, alcohol esters, sugar esters, glycerides, fatty-chain phenol derivatives, polyols, and combinations thereof. 
     
     
         19 . The process of  claim 18 , wherein the polyols are selected from the group consisting of sugars, alkyl polyglycosides, polyphenols, and combinations thereof. 
     
     
         20 . The process of  claim 12 , wherein the compound of the formula R-OH is selected from the group consisting of octanoic acid; nonanoic acid; decanoic acid; undecanoic acid; undecylenic acid; dodecanoic acid; tetradecanoic acid; hexadecanoic acid; octadecanoic acid; 9-octadecenoic acid; 9,12-octadecadienoic acid; 9,12,15-octadecatrienoic acid; arachidic acid; arachidonic acid; behenic acid; erucic acid; octanols; nonanols; decanols; undecanols; undecenols; dodecanols; tetradecanols; hexadecanols; octadecanols; oleyl alcohol; sorbitol esters; sorbitan esters; sorbitol ethers; sorbitan ethers; isosorbide monoesters; isomannide monoesters; isoidide monoesters; isosorbide monoethers; isomannide monoethers; isoidide monoethers; hydroxyethyl oleate; cardanol; polyacids; tannins; lignans; lignins and other natural polyols; polyols derived from natural products; and combinations thereof. 
     
     
         21 . The process of  claim 12 , wherein the alkylene oxide is selected from the group consisting of ethylene oxide, propylene oxide, butylene oxide, and combinations thereof. 
     
     
         22 . The process of  claim 12 , wherein the alkylene oxide is ethylene oxide. 
     
     
         23 . The process of  claim 12 , wherein the catalyst is a basic or alkaline catalyst selected from the group consisting of sodium hydroxide, potassium hydroxide, sodium alkoxides, potassium alkoxides, and combinations thereof. 
     
     
         24 . The process of  claim 23 , wherein the basic or alkaline catalyst comprises potassium hydroxide. 
     
     
         25 . The process of  claim 12 , wherein the acid having a pK a  of less than or equal to 3.5 is a mineral Brønsted acid, an organic Brønsted acid, a mineral Lewis acid, or an organic Lewis acid. 
     
     
         26 . The process of  claim 12 , wherein the acid having a pK a  of less than or equal to 3.5 is selected from the group consisting of hydrochloric acid, sulfuric acid, nitric acid, phosphoric acid, sulfamic acid, p-toluenesulfonic acid, alkanesulfonic acid, and combinations thereof. 
     
     
         27 . The process of  claim 12 , wherein the acid having a pK a  of less than or equal to 3.5 is selected from the group consisting of methanesulfonic acid, ethanesulfonic acid, n-propanesulfonic acid, isopropanesulfonic acid, n-butanesulfonic acid, isobutanesulfonic acid, sec-butanesulfonic acid, tert-butanesulfonic acid, and combinations thereof. 
     
     
         28 . The process of  claim 27 , wherein the acid having a pK a  of less than or equal to 3.5 is methanesulfonic acid. 
     
     
         29 . The process of  claim 12 , wherein the compound of formula (I) is an alkoxylate selected from group consisting of:
 C 16 -C 18  alcohol with 33 OE;   C 10  oxo alcohol with 20 OE;   C 16 -C 18  alcohol with 18 OE;   (C 18 ) oleyl alcohol with 20 OE;   stearic acid ethoxylated with 120 OE;   rapeseed oil with 20 OE;   rapeseed oil with 30 OE;   hydrogenated castor oil with 25 OE;   hydrogenated castor oil with 20 OE;   ester of sorbitan monolaurate with 20 OE;   ester of sorbitan monostearate with 20 OE;   ester of sorbitan monooleate with 20 OE; and   coconut fatty acid with 150 OE.